Organic light-emitting diode display and manufacturing method thereof

ABSTRACT

An organic light-emitting diode (OLED) display and a manufacturing method thereof are disclosed. One inventive aspect includes a first substrate, a second substrate, and a first insulation layer, a metal layer and a second insulation layer formed on the first insulation layer. The metal layer is formed on the first insulating layer and has a first through hole. The second insulation layer is formed on the metal layer and has a second through hole.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/745,052, filed on Jun. 19, 2015, now U.S. Pat. No. 9,385,174, whichis a continuation in part of U.S. patent application Ser. No.14/203,355, filed on Mar. 10, 2014, now U.S. Pat. No. 9,184,224, issuedNov. 10, 2015, which claims priority under 35 U.S.C. §119 to KoreanPatent Application No. 10-2013-0126113 filed on Oct. 22, 2013, thedisclosures of which are incorporated by reference herein in theirentireties.

BACKGROUND

Field

Various aspects of the disclosed technology relate to an organiclight-emitting diode (OLED) display and a manufacturing method thereofwith reduced dead space and improved substrates sealing.

Description of the Related Technology

Displays are the apparatuses for providing visual information such asimages or pictures to a user. Particularly, organic light-emitting diode(OLED) displays, which are self-emitting displays that electricallyexcite an organic compound to emit light, have attracted much attentionas next-generation display. This is because OLED displays can be drivenat a low voltage. In addition, OLED displays can be made with a thinprofile and have advantages such as wide viewing angles, fast responsespeeds, etc. This features overcome the limitations of traditionalliquid crystal displays.

In the OLED display, a sealing member can be used to bond a lowersubstrate and an upper substrate. However, the area in which the sealingmember is formed can be a dead space on which images or pictures cannotbe displayed. Thus, methods for reducing the dead space and improvingbonding force are widely desired.

SUMMARY OF CERTAIN INVENTIVE ASPECTS

One or more embodiments of the disclosed technology include an organiclight-emitting diode (OLED) display that is capable of improved bondingand a method of manufacturing the same.

One or more embodiments of the disclosed technology include an OLEDdisplay that is capable of reducing a dead space and a method ofmanufacturing the same.

Additional aspects will be set forth in part in the description whichfollows and, in part, will be apparent from the description, or can belearned by practice of the presented embodiments.

According to one aspect of the disclosed technology, an OLED displayincludes: a first substrate including a display area and a peripheralarea; a second substrate facing the first substrate; a sealing memberconfigured to adhere the first substrate to the second substrate; and afirst insulation layer, a metal layer and a second insulation layerdeposited on the first substrate, wherein the metal layer is depositedon the first insulation layer and has at least a first through hole inthe peripheral area, wherein the second insulation layer is deposited onthe metal layer and has at least one second through hole that has adiameter different from that of the first through hole, wherein at leastone portion of the second through hole overlaps with at least oneportion of the first through hole, and wherein the sealing member fillseach of the first and second through holes.

The metal layer can contact the sealing member.

A third through hole can be defined in the first insulation layer andoverlaps the first through hole, and wherein the third through hole canhave a diameter less than that of the first through hole.

The second and third through holes can have the same diameter.

The second through hole can have a diameter less than that of the firstthrough hole.

The metal layer can be deposited of the same material as a data lineapplying a data signal to the display area.

The display area can comprise a transistor, a capacitor, and an organiclight-emitting diode (OLED), and the OLED can be driven according to thedata signal.

The sealing member can have a maximum width of about 750 μm or less.

The first through hole can have a radius greater by about 3 μm or morethan that of the second through hole.

The OLED display further includes a gold (Au) layer contacting a sidesurface of the sealing member.

The Au layer can include at least one of a first Au layer contacting theinside of the sealing member and a second Au layer contacting theoutside of the sealing member.

The sealing member further can include a plurality of sealing branchessurrounding the display area, wherein one end of each of the sealingbranches adheres to the first substrate and the second substrate.

The other end can be exposed to the environment.

The sealing branches can be spaced apart from each other.

The OLED display further includes a reinforcing material to reinforcethe adhesion between the first and second substrates, wherein thereinforcing material fills the space between two adjacent sealingbranches.

The reinforcing material can be deposited of a polymer resin.

At least one of the sealing branches perpendicularly can contact thesealing member.

According to another aspect of the disclosed technology, a method ofmanufacturing an OLED display includes: forming a first substrate havinga display area and a peripheral area surrounding the display area;forming a first insulation layer on the peripheral area of the firstsubstrate; forming a metal layer on the first insulation layer; forminga second insulation layer on the metal layer; forming a first throughhole through the first insulation layer, the metal layer and the secondinsulation layer; forming a second through hole having a diameterdifferent from that of the first through hole in the metal layer; andfilling the first and second through holes with a sealing material so asto seal the first substrate to a second substrate.

The first through hole can be formed through a dry etch process.

The second through hole can be formed through a wet etch process.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects will become apparent and more readilyappreciated from the following description of the embodiments, taken inconjunction with the accompanying drawings in which:

FIG. 1 is a plan view of an organic light-emitting diode (OLED) displayaccording to an embodiment of the disclosed technology;

FIG. 2 is a cross-sectional view taken along line I-I of FIG. 1;

FIG. 3 is a detailed view of a display unit and a sealing member of FIG.1;

FIG. 4 is a schematic plan view of the sealing member of FIG. 3;

FIG. 5 is a schematic cross-sectional view illustrating a portion of anOLED display according to another embodiment of the disclosedtechnology;

FIG. 6 is a schematic view illustrating a portion of an OLED displayaccording to further another embodiment of the disclosed technology; and

FIGS. 7A to 7D are views of a process for manufacturing an OLED displayaccording to an embodiment of the disclosed technology.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

Hereinafter, exemplary embodiments of the disclosed technology will bedescribed in detail with reference to the accompanying drawings. Thedisclosed technology can, however, be embodied in different forms andshould not be construed as limited to the embodiments set forth herein.Rather, these embodiments are provided so that this disclosure will bethorough and complete, and will fully convey the scope of the disclosedtechnology to those skilled in the art. Sizes of elements in thedrawings can be exaggerated for convenience of explanation. In otherwords, since sizes and thicknesses of components in the drawings arearbitrarily illustrated for convenience of explanation, the followingembodiments are not limited thereto.

In the following exemplary implementations, the x-axis, the y-axis andthe z-axis are not limited to three axes of the rectangular coordinatesystem, and can be interpreted in a broader sense. In one exemplaryimplementation, the x-axis, the y-axis, and the z-axis canareperpendicular to one another, or can represent different directions thatare not perpendicular to one another.

It will be understood that although the terms of first and second areused herein to describe various elements, these elements should not belimited by these terms. Terms are only used to distinguish one componentfrom other components.

In the following description, technical terms are used only to explain aspecific exemplary embodiment while not limiting the disclosedtechnology. The terms of a singular form may include plural forms unlessreferred to the contrary. The terms “include,” “comprise,” “including,”and “comprising,” as used herein, specify a component, a process, anoperation, and/or an element but do not exclude other components,processes, operations, and/or elements. It will be understood thatalthough the terms “first” and “second” are used herein to describevarious elements, these elements should not be limited by these terms.These terms are only used to distinguish one component from othercomponents.

It will be understood that when a layer, region, or component isreferred to as being “formed on,” another layer, region, or component,it can be directly or indirectly formed on the other layer, region, orcomponent. That is, for example, intervening layers, regions, orcomponents may be present.

The drawings and description are to be regarded as illustrative innature and not restrictive. Like reference numerals designate likeelements throughout the specification.

Further, since sizes and thicknesses of constituent members shown in theaccompanying drawings are arbitrarily given for better understanding andease of description, the disclosed technology is not limited to theillustrated sizes and thicknesses.

In the drawings, the thickness of layers, films, panels, regions, etc.,are exaggerated for clarity. In the drawings, for better understandingand ease of description, the thicknesses of some layers and areas areexaggerated. It will be understood that when an element such as a layer,film, region, or substrate is referred to as being “on” another element,it is directly on the other element or intervening elements may also bepresent.

Throughout this specification and the claims that follow, when it isdescribed that an element is “connected” to another element, the elementis “directly connected” to the other element or “electrically connected”to the other element through a third element. In addition, unlessexplicitly described to the contrary, the word “comprise” and variationssuch as “comprises” or “comprising” will be understood to imply theinclusion of stated elements but not the exclusion of any otherelements. Throughout this specification, it is understood that the term“on” and similar terms are used generally and are not necessarilyrelated to a gravitational reference.

Here, when a first element is described as being connected to a secondelement, the first element is not only directly connected to the secondelement but may also be indirectly connected to the second element via athird element. Further, some of the elements that are not essential tothe complete understanding of the disclosed technology are omitted forclarity. Also, like reference numerals refer to like elementsthroughout.

FIG. 1 is a plan view of an organic light-emitting diode (OLED) displayaccording to an embodiment of the disclosed technology, and FIG. 2 is across-sectional view taken along line I-I of FIG. 1.

Referring to FIGS. 1 and 2, an OLED display includes a first substrate10, a second substrate 20 facing the first substrate 10, and a sealingmember 30. The first substrate 10 includes a display unit 40. Thesealing member 30 surrounds the display unit 40 and bonds the firstsubstrate 10 to the second substrate 20.

The first substrate 10 can be classified into a display area DA on whichthe display unit 40 is formed and a peripheral area PA surrounding thedisplay area DA. The substrate 10 can be formed of a transparent glassmaterial that contains SiO₂ as a main component. However, the embodimentof the disclosed technology is not limited thereto. In one exemplaryimplementation, the substrate 10 is formed of a transparent plasticmaterial. The substrate 10 can be a flexible substrate havingflexibility. In another exemplary implementation, the flexible substrateis manufactured by using a polymer material such as a material that islightweight due to low specific gravity, break-resistant, and bendablewhen compared to those of the glass substrate, such as, a flexibleplastic film.

The display unit 40 of the first substrate 10 can include a transistorTR that is a thin film transistor for driving, a capacitor Cst, and anorganic light-emitting diode (OLED) on the substrate 10. The displayunit 40 will be described later in detail.

The second substrate 20 can correspond to the first substrate 10. Thesecond substrate 20 can be formed of various materials such as glassmaterials, metal materials, or plastic materials. The first substrate 10and the second substrate 20 are bonded to each other by using thesealing member 30. The sealing member 30 can include glass frit.

In detail, the sealing member 30 can surround the display unit 40 and beformed around the display unit 40. The sealing member 30 can seal thedisplay unit 40 to protect the display unit 40 from the outside.

FIG. 3 is a detailed view of the display unit 40 and the sealing member30 of FIG. 1, and FIG. 4 is a schematic plan view of the sealing member30 of FIG. 3.

Referring to FIGS. 3 and 4, a buffer layer 11 canis further formed onthe substrate 10. The buffer layer 11 can be formed of an inorganicmaterial such as SiO_(x), SiN_(x), SiON, AlO, or AlON, or an organicmaterial such as acrylic or polyimide. Alternatively, the inorganicmaterial and the organic material can be alternately laminated on eachother to form the buffer layer 11. The buffer layer 11 can block oxygenand moisture. Thus, the buffer layer 11 can prevent moisture orimpurities generated from the substrate 10 from being diffused andadjust a thermal transfer rate when crystallized to facilitatecrystallization of a semiconductor.

The display unit 40 of the first substrate 10 includes the transistor TRthat is the thin film transistor for driving, the capacitor Cst, and theOLED on the substrate 10. In detail, the transistor TR is formed on thebuffer layer 11. Although a bottom gate type thin film transistor isexemplified in the embodiment, a thin film transistor having a differentstructure such as a top gate type thin film transistor can be provided.

An active layer 212 is formed on the buffer layer 11. When the activelayer 212 is formed of poly-silicon, amorphous silicon can be formed andthen crystallized to change the amorphous silicon into the poly-silicon.

A method of crystallizing the amorphous silicon can include variousmethods such as a rapid thermal annealing (RTA) method, a solid phasecrystallization (SPC) method, an eximer laser annealing (ELA) method, ametal induced crystallization (MIC) method, a metal induced lateralcrystallization (MILC) method, a sequential lateral solidification (SLS)method, and the like. Here, a method in which a high-temperature heatingprocess is not required can be used so as to be applied to the substrateaccording to the embodiment of the disclosed technology.

In one exemplary implementation, when crystallized by using a lowtemperature poly-silicon (LTPS) process, the laser is irradiated ontothe active layer 212 for a short time to activate the active layer 212.Here, the whole process can be performed below a temperature of about300° C. to prevent the substrate 10 from being exposed at a hightemperature of about 300° C. or more. Thus, the substrate formed of thepolymer material can be applied to form the transistor TR.

N-type or P-type impurity ions can be doped into the active layer 212 toform a source region 212 b and a drain region 212 a. A channel region212 c in which impurities are not doped is formed between the sourceregion 212 b and the drain region 212 a. A gate insulation layer 13 isformed on the active layer 212. The gate insulation layer 13 can have asingle layer structure of SiO₂ or a double layer structure of SiO₂ andSiN_(x).

A gate electrode 214 is formed on a predetermined area of the gateinsulation layer 13. The gate electrode 214 is connected to a gate line(not shown) that applies a transistor on/off signal. The gate electrode214 can be provided in a single or multiple conductive layer.

A drain electrode 216 a and a source electrode 216 b are formed on thegate electrode 214 with an interlayer dielectric 15 therebetween. Thedrain electrode 216 a and source electrode 216 b are respectivelyconnected to the source region 212 b and the drain region 212 a of theactive layer 212. The interlayer dielectric 15 can be formed of aninsulating material such as SiO₂ or SiN_(x). Alternatively, theinterlayer dielectric 15 can be formed of an insulating organicmaterial.

A pixel defining layer 18 is formed on the interlayer dielectric 15 tocover the drain electrode 216 a and the source electrode 216 b. Also, apixel electrode 114 formed of the same transparent conductive materialas the gate electrode 214 can be formed on the buffer layer 11 and thegate insulation layer 13. Each of the drain electrode 216 a and thesource electrode 216 b can have resistance less than that of the gateelectrode 214.

In the pixel electrode 114, at least one of metals having a low workfunction, i.e., Li, Ca, LiF/Ca, LiF/Al, Al, Mg, and compounds thereofcan be deposited on an intermediate layer 119. Then, an auxiliaryelectrode formed of a material for forming a transparent electrode suchas ITO, IZO, ZnO, or In₂O₃ can be formed on the intermediate layer 119on which the metal is deposited. However, the pixel electrode 114 is notlimited thereto. In one exemplary implementation, the pixel electrode114 canis a reflective electrode.

A portion of the pixel defining layer 18 is etched to form theintermediate layer 119 on the pixel electrode 114. The intermediatelayer 119 can include an organic emission layer to emit visible light.

An opposite electrode 19 as a common electrode is formed on theintermediate layer 119. Voltages having polarities different from eachother can be applied to the intermediate layer 119 to emit light.

The organic emission layer of the intermediate layer 119 can be formedof a low-molecular organic material or a high-molecular organicmaterial.

When the organic emission layer of the intermediate layer 119 is formedof the low-molecular organic material, the intermediate layer 119 canhave a single layer or multilayer structure of at least one of a holeinjection layer (HIL), a hole transport layer (HTL), an electrontransport layer (ETL), and an electron injection layer (EIL).

Also, the organic material that is capable of being used for theintermediate layer 119 can include copper phthalocyanine (CuPc),N,N′-Di(naphthalene-1-yl)-N,N′-diphenyl-benzidine (NPB),tris-8-hydroxyquinoline aluminum (Alq3), or the like. The low-molecularorganic material can be formed through a vacuum deposition method usingmasks.

When the organic emission layer of the intermediate layer 119 is formedof the high-molecular organic material, the intermediate layer 119 canhave a structure including the HTL and the EML. Here, the HTL can beformed of PEDOT. The light emission layer can be formed of apoly-phenylenevinylene (PPV)-based or polyfluorene-based high-molecularorganic material. The high-molecular organic material can be formedthrough a screen printing method or inkjet printing method. However, theintermediate layer 119 is not limited thereto, and thus variousembodiments can be applied to the intermediate layer 119.

The opposite electrode 19 can be provided as a transparent electrode orreflective electrode, like the pixel electrode 114. When the oppositeelectrode 19 is used as the transparent electrode, in the oppositeelectrode 19, at least one of metals having a low work function, i.e.,Li, Ca, LiF/Ca, LiF/Al, Al, Mg, and compounds thereof can be depositedon an intermediate layer 119. Then, an auxiliary electrode formed of amaterial for forming a transparent electrode such as ITO, IZO, ZnO, orIn₂O₃ can be formed on the intermediate layer 119 on which the metal isdeposited.

When the opposite electrode 19 is used as the reflective electrode, theopposite electrode 19 can be formed by entirely depositing at least oneof Li, Ca, LiF/Ca, LiF/Al, Al, Mg, and compounds thereof.

When the pixel electrode 114 is provided as the transparent electrode orreflective electrode, the pixel electrode 114 can have a shapecorresponding to an opened shape of each of pixels. The oppositeelectrode 19 can be formed by entirely depositing the transparentelectrode or reflective electrode on an entire display area. It is notnecessary to entirely deposit the transparent electrode or reflectiveelectrode on the opposite electrode 19. In some exemplaryimplementations, the transparent electrode or reflective electrode canisdeposited on the opposite electrode 19 in various patterns. Here, thepixel electrode 114 and the opposite electrode 19 can be laminated onpositions opposite to each other.

In the OLED display according to a current embodiment, the pixelelectrode 114 canis used as an anode. The opposite electrode 19 canisused as cathode. Here, the polarities of the pixel electrode 114 and theopposite electrode 19 canare applied in reverse.

In the peripheral area of the first substrate 10, a first insulationlayer 410, a metal layer 430 formed on the first insulation layer 410and having at least one through hole TH1 in the peripheral area, and asecond insulation layer 450 formed on the metal layer 430 and having asecond through hole TH2 having a radius less than that of the firstthrough hole TH1. The sealing member 30 can be filled into the first andsecond through holes TH1 and TH2 to bond the first substrate 10 to thesecond substrate 20. Here, the first insulation layer 410 can be formedof the same material as at least one of the buffer layer 11 and the gateinsulation layer 13. The second insulation layer 450 can be formed ofthe same as the interlayer dielectric 15. Although the buffer layer 11and the gate insulation layer 13 are provided as the first insulationlayer 410 in FIG. 3, the embodiment of the disclosed technology is notlimited thereto. In some exemplary implementations, only the gateinsulation layer 13 canis provided as the first insulation layer 410.

Also, the first insulation layer 410 can overlap the first through holeTH1 to form a third through hole TH3 having a radius less than that ofthe first through hole TH1. Although the second and third through holesTH2 and TH3 have the same radius as each other in FIG. 3, the embodimentof the disclosed technology is not limited thereto. The third throughhole TH3 can have a radius greater or less than that of the secondthrough hole TH2. However, since the second and third through holes TH2and TH3 overlap the first through hole TH1, each of the second and thirdthrough holes TH2 and TH3 can have a radius less than that of the firstthrough hole TH1.

The metal layer 430 formed between the first insulation layer 410 andthe second insulation layer 450 can be formed of the same material asthe gate electrode 214 of the above-described thin film transistor TFT.In detail, the metal layer 430 can be formed on the same layer as thegate electrode 214. In one exemplary implementation, the metal layer 430can extend from the gate electrode 214.

In FIG. 3, the metal layer 430 is formed on the gate insulation layer13, like the gate electrode 214. In some implementations, the metallayer 430 canis formed of the same material as the drain or sourceelectrode 216 a or 216 b of the thin film transistor TFT and can beformed on the same layer as the drain or source electrode 216 a or 216b. Alternatively, the metal layer 430 may be formed of the same materialas a data line (not shown). The data line may apply a data signalprovided by a data driving unit (not shown) arranged in the peripheralarea to the display area DA. The OLED in the display area DA is drivenaccording to the data signal. For convenience of description, theimplementation in which the metal layer 430 is formed of the samematerial as the gate electrode 214 and formed on the same layer as thegate electrode 214 will be described below.

When the first and second substrates 10 and 20 are bonded to each otherby using the sealing member 30, ultraviolet (UV) light or laser beamscan be irradiated to cure the sealing member 30. In detail, the UV lightor laser beams can pass through the second substrate 20. Then, the UVlight or laser beams can be irradiated onto the sealing member 30. Thus,the metal layer 430 is formed under the sealing member 30, the UV lightor laser beams passing through the sealing member 30 can be reflectedfrom the metal layer 430 and thus emitted again toward the sealingmember 30 to improve irradiation efficiency of the UV light or laserbeams. However, the bonded sealing member 30 can be limited in width dueto a limitation in irradiation width of the UV light or laser beams.Generally, the sealing member 30 can have a width of about 750 μm orless.

An area of the sealing member 30 contacting the second substrate 20 canbe easily observed through the second substrate 20 formed of atransparent material. On the other hand, an area of the sealing member30 contacting the first substrate 30 can not be observed by the metallayer 430 formed of an opaque material. Thus, since the meal layer 430has the at least one first through hole TH1, the contact area betweenthe sealing member 30 and the first substrate 10 can be observed.

In addition, since the first through hole TH1 of the metal layer 430 hasa radius greater than that of each of the second and third through holesTH2 and TH3 adjacent to the metal layer 430, the first and secondinsulation layers 410 and 450 can hold the sealing member 30 filled intothe first through hole TH1. The first through hole TH1 can have a radiusgreater by about 3 μm or more than that of each of the second and thirdthrough holes TH2 and TH3. Thus, the bonding areas of the first andsecond insulation layers 410 and 450 and the metal layer 430 withrespect to the sealing member 30 can increase, and also, delamination ofthe sealing member 30 from the first insulation layer 410, the secondinsulation layer 450, or the metal layer 430 can be prevented.

In FIGS. 3 and 4, one first through hole TH1, one second through holeTH2, and one third through hole TH3 canare defined in a width directionof the sealing member 30. However, the embodiment of the disclosedtechnology is not limited thereto. In some exemplary implementations, aplurality of first through holes TH1, a plurality of second throughholes TH2, and a plurality of third through holes TH3 canare defined inthe width direction of the sealing member 30.

FIG. 5 is a schematic cross-sectional view illustrating a portion of anOLED display according to another embodiment of the disclosedtechnology. Unlike the OLED display of FIG. 3, the OLED display of FIG.5 canfurther includes a gold (Au) layer 60 contacting a sealing member30 to reduce a dead space. When a display area DA is defined as theinside of the sealing member 30, and a peripheral area PA is defined asthe outside of the sealing member 30 with respect to the sealing member30, the Au layer 60 can include a first Au layer 61 contacting theinside of the sealing member 30 and a second Au layer 62 contacting theoutside of the sealing member 30.

Although the first and second Au layers 61 and 62 are illustrated inFIG. 5, the embodiment of the disclosed technology is not limitedthereto. In some exemplary implementations, the Au layer 60 canincludesonly the first Au layer 61 or only the second Au layer 62. Also, the Aulayer 60 can be formed on the same layer as a portion of the sealingmember 30 on a first substrate 10. In one exemplary implementation, anedge area of the sealing member 30 canis formed on a second insulationlayer 450, and the Au layer 60 can also be formed to contact the sealingmember on the second insulation layer 450.

Since the Au layer 60 has flexibility, the Au layer 60 can have superioradhesion with respect to the sealing member 30 formed of glass frit. Indetail, when laser processing is performed, the Au layer 60 can increasein volume to adhere to the sealing member 30 while filling a spacebetween the Au layer 60 and the sealing member 30. Also, since gold (Au)is not naturally oxidized, the Au layer 60 can prevent the sealingmember 30 from contacting external air to prevent the sealing member 30from being oxidized or volatilized. Thus, the Au layer 60 can realizethe sealing member 30 to have a small area and therefore, reduce thedead space. In one exemplary implementation, the sealing member 30 canismanufactured with a width of about 680 μm or less.

FIG. 6 is a schematic view illustrating a portion of an OLED displayaccording to further another embodiment of the disclosed technology.When compared to FIG. 3, an OLED display of FIG. 6 canincludes aplurality of sealing branches 32. Each of the sealing branches 32 canhasone end contacting the sealing member 30 and the other end that does notcontact the sealing member 30. A first substrate 10 canadheres to asecond substrate 20 by the sealing branches 32. The sealing branch 32can be formed of the same material as the sealing member 30. In someexemplary implementations, each of the sealing member 30 and the sealingbranch 32 caninclude glass frit.

Particularly, the sealing member 30 can seal a display unit 40 toprotect the display unit from the outside. Also, the sealing branch 32can formed outside the sealing member 30. Here, the sealing branch 32can have one end 32E1 contacting the sealing member 30 and the other end32E2 exposed to the outside.

Since the sealing branch 32 is provided in addition to the sealingmember 30, a contact area between the sealing material and the first andsecond substrates 10 and 20 can increase. Also, since the contact areaincreases, adhesion force between the first and second substrates 10 and20 can increase. Although the contact area increases when the sealingmember 30 is formed on an entire peripheral area except for a pad unit50, cracks can occur. Thus, the OLED display according to an embodimentcan include the sealing branches 32 so that the contact area increases,and also, the occurrence of the cracks is prevented.

Also, the sealing branches 32 can be spaced apart from each other. Atleast one of the sealing branches 32 can vertically contact the sealingmember 30. In one exemplary implementation, at least one of the sealingbranches 32 canhas a longitudinal direction perpendicular to a normalline of the sealing member 30. Although the sealing branches 32vertically contact the sealing member 30 in FIG. 6, the embodiment ofthe disclosed technology is not limited thereto. In another exemplaryimplementation, a portion of the sealing branches 32 canisperpendicularly formed with respect to the sealing member 30. The otherportion of the sealing branches 32 canis inclinedly formed with respectto the sealing member 30. Since the sealing branch 32 is inclinedlyformed with respect to the sealing member 30, the contact area betweenthe sealing member 30 and the first and second substrates 10 and 20 canfurther increase.

A reinforcing material 70 for supplementing the adhesion of the sealingbranches 32 can be formed between the two adjacent sealing branches 32.The reinforcing material 70 can be formed of a resin, such as, a polymerresin. The reinforcing material 70 can supplement mechanical strengththat is weakened by thermal shock and stress which can occur due tothermal mismatch between the glass frit of the sealing member 30 and theglass of each of the first and second substrates 10 and 20.

Although the OLED display is described so far, the embodiments of thedisclosed technology are not limited thereto. In one exemplaryimplementation, a method of manufacturing the OLED display canalsobelongs to the scope of the prevent invention.

FIGS. 7A to 7D are views of a process for manufacturing an OLED displayaccording to an embodiment of the disclosed technology.

To manufacture an OLED display, a first substrate 10 having a displayarea DA and a peripheral area PA surrounding the display area DA isprepared. Then, a display unit and a pad unit are formed on the firstsubstrate 10. In one exemplary implementation, a buffer layer 11, a gateinsulation layer 13, a metal layer 430, and an interlayer dielectric 15canare formed over the display area DA and the peripheral area PA of thefirst substrate 10. Then, an organic light-emitting diode (OLED), atransistor TR, and a capacitor Cst can be formed on the display area DA.Particularly, as shown in FIG. 7A, a first insulation layer 410, a metallayer 430, and a second insulation layer 450 canare successively formedon the first substrate 10 on the peripheral area PA. Here, the firstinsulation layer 410 canis formed of the same material as at least oneof the buffer layer 11 and the gate insulation layer 13. The metal layer430 canis formed of the same material as an electrode of the transistorTR. The second insulation layer 450 canis formed of the same material asthe interlayer dielectric 15.

Also, as shown in FIG. 7B, second and third through holes TH2 and TH3can be formed in the first insulation layer 410, the metal layer 430,and the second insulation layer 450 which are formed on the peripheralarea PA of the first substrate 10. The second and third through holesTH2 and TH3 can be formed through a dry etch process. The second andthird through holes TH2 and TH3 can have the same size. Also, a throughhole can be formed in the meal layer 430.

As shown in FIG. 7C, a first through hole TH1 canis formed in the metallayer 430. The first through hole TH1 can be formed through a wet etchprocess. A solution containing molybdenum (Mo) can be used as etchant.When a predetermined time elapses after the etchant is introduced intothe second through hole TH2, a side surface of the metal layer 430 canbe etched by the etchant to form the first through hole TH1 in the metallayer 430. The wet etch process can be performed so that the firstthrough hole TH1 has a radius greater by about 3 μm or more than that ofthe second through hole TH2.

As shown in FIG. 7D, a material for forming the sealing member 30 canisfilled into the first and second through holes TH1 and TH2. Then, thefirst substrate 10 and a second substrate 20 corresponding to the firstsubstrate 10 canadhere to each other by using the sealing member 30. Thefirst and second substrates 10 and 20 are aligned with each other. Then,when UV light or laser beams are irradiated onto an upper portion of thesecond substrate 20, the sealing member 30 between the first and secondsubstrates 10 and 20 are cured. When the UV light or laser beams areirradiated onto the sealing member 30, the metal layer 430 overlappingthe sealing member 30 on the first substrate 10 can reflect the UV lightor laser beams. Thus, the sealing member 30 can be primarily cured bythe UV light or laser beams that are irradiated from an upper side ofthe second substrate 20. Them, the sealing member 30 can be secondarilycured by the UV light or laser beams that are reflected by the metallayer 430. Therefore, the sealing member 30 can be firmly cured. Inaddition, since the first and second insulation layers 410 and 450 holdthe sealing member 30 filled into the first through hole TH1,delamination of the sealing member 30 can be reduced.

As described above, according to the embodiments of the disclosedtechnology, the OLED display can be improved in adhesion force.

Also, the dead space of the OLED display can be reduced.

In addition, the oxidation and volatilization of the sealing member canbe prevented.

For purposes of summarizing the disclosed technology, certain aspects,advantages and novel features of the disclosed technology have beendescribed herein. It is to be understood that not necessarily all suchadvantages is achieved in accordance with any particular embodiment ofthe disclosed technology. Thus, the disclosed technology is embodied orcarried out in a manner that achieves or optimizes one advantage orgroup of advantages as taught herein without necessarily achieving otheradvantages as is taught or suggested herein.

Various modifications of the above described embodiments will be readilyapparent, and the generic principles defined herein is applied to otherembodiments without departing from the spirit or scope of the disclosedtechnology. Thus, the disclosed technology is not intended to be limitedto the embodiments shown herein but is to be accorded the widest scopeconsistent with the principles and novel features disclosed herein.

While one or more embodiments of the disclosed technology have beendescribed with reference to the figures, it will be understood by thoseof ordinary skill in the art that various changes in form and detailscan be made therein without departing from the spirit and scope of thedisclosed technology as defined by the following claims.

What is claimed is:
 1. An organic light-emitting diode (OLED) displaycomprising: a first substrate including a display area and a peripheralarea; a second substrate facing the first substrate; a sealing memberconfigured to adhere the first substrate to the second substrate; and afirst insulation layer, a metal layer and a second insulation layerdeposited on the first substrate, wherein the metal layer is depositedon the first insulation layer and has at least a first through hole inthe peripheral area, wherein the second insulation layer is deposited onthe metal layer and has at least one second through hole that has adiameter different from that of the first through hole, wherein at leastone portion of the second through hole overlaps with at least oneportion of the first through hole, and wherein the sealing member fillseach of the first and second through holes.
 2. The OLED display of claim1, wherein the metal layer contacts the sealing member.
 3. The OLEDdisplay of claim 1, wherein a third through hole is defined in the firstinsulation layer and overlaps the first through hole, and wherein thethird through hole has a diameter less than that of the first throughhole.
 4. The OLED display of claim 3, wherein the second and thirdthrough holes have the same diameter.
 5. The OLED display of claim 1,wherein the second through hole has a diameter less than that of thefirst through hole.
 6. The OLED display of claim 1, wherein the metallayer is deposited of the same material as a data line applying a datasignal to the display area.
 7. The OLED display of claim 6, wherein thedisplay area comprises a transistor, a capacitor, and an organiclight-emitting diode (OLED), and the OLED is driven according to thedata signal.
 8. The OLED display of claim 1, wherein the sealing memberhas a maximum width of about 750 μm or less.
 9. The OLED display ofclaim 1, wherein the first through hole has a radius greater by about 3μm or more than that of the second through hole.
 10. The OLED display ofclaim 1, further comprising a gold (Au) layer contacting a side surfaceof the sealing member.
 11. The OLED display of claim 10, wherein the Aulayer comprises at least one of a first Au layer contacting the insideof the sealing member and a second Au layer contacting the outside ofthe sealing member.
 12. The OLED display of claim 1, wherein the sealingmember further comprises a plurality of sealing branches surrounding thedisplay area, wherein one end of each of the sealing branches adheres tothe first substrate and the second substrate.
 13. The OLED display ofclaim 12, wherein the other end is exposed to the environment.
 14. TheOLED display of claim 12, wherein the sealing branches are spaced apartfrom each other.
 15. The OLED display of claim 12, further comprising areinforcing material to reinforce the adhesion between the first andsecond substrates, wherein the reinforcing material fills the spacebetween two adjacent sealing branches.
 16. The OLED display of claim 15,wherein the reinforcing material is deposited of a polymer resin. 17.The OLED display of claim 12, wherein at least one of the sealingbranches perpendicularly contacts the sealing member.
 18. A method ofmanufacturing an organic light-emitting diode (OLED) display, the methodcomprising: forming a first substrate having a display area and aperipheral area surrounding the display area; forming a first insulationlayer on the peripheral area of the first substrate; forming a metallayer on the first insulation layer; forming a second insulation layeron the metal layer; forming a first through hole through the firstinsulation layer, the metal layer and the second insulation layer;forming a second through hole having a diameter different from that ofthe first through hole in the metal layer; and filling the first andsecond through holes with a sealing material so as to seal the firstsubstrate to a second substrate.
 19. The method of claim 18, wherein thefirst through hole is formed through a dry etch process.
 20. The methodof claim 18, wherein the second through hole is formed through a wetetch process.